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DOE OSTI2011

Range Fuels Inc/ Range Fuels Soperton Plant LLC Final Technical Report

Range Fuels Soperton Plant LLC (Recipient) signed an amended TIA with the DOE to help facilitate the design, construction, and operation of a commercial scale biorefinery for production of biofuels and other products in a replicable, commercial, integrated biorefinery process that will meet or exceed DOE requirement as required in the FOA for processing at least 700 dry (metric) tonnes per day (772 dry short tons per day) of lignocellulosic feedstocks from forestry waste and timber. Construction of the Project was to be carried out in two distinct phases. During Phase 1, a module with a Design Capacity of 125 dry tons per day was to be constructed and operated to demonstrate commercial scale operational and technological viability and provide data for Project design optimization. Phase 2 would consist of five additional modules with a combined Design Capacity of at least 650 dry tons per day incorporating Phase 1 into an integrated facility with a total Design Capacity of 775 dry tons per day meeting or exceeding DOE's commercial throughput requirements for the Project. This funding is intended to partially reimburse the initial construction, commissioning and startup, and operating costs for this first-of-its-kind integrated biorefinery and enable the development of a biofuels industry. This purpose is consistent with Section 932 of the Energy Policy Act of 2005. The plant was built on schedule and under budget.

09 BIOMASS FUELS↗

NASA NTRS2010

Streamlining Payload Integration

Payload integration onto space transport vehicles and the International Space Station (ISS) is a complex process. Yet, cargo transport is the sole reason for any space mission, be it for ferrying humans, science, or hardware. As the largest such effort in history, the ISS offers a wide variety of payload experience. However, for any payload to reach the Space Station under the current process, Payload Developers face a list of daunting tasks that go well beyond just designing the payload to the constraints of the transport vehicle and its stowage topology. Payload customers are required to prove their payload s functionality, structural integrity, and safe integration - including under less than nominal situations. They must also plan for or provide training, procedures, hardware labeling, ground support, and communications. In addition, they must deal with negotiating shared consumables, integrating software, obtaining video, and coordinating the return of data and hardware. All the while, they must meet export laws, launch schedules, budget limits, and the consensus of more than 12 panel and board reviews. Despite the cost and infrastructure overhead, payload proposals have increased. Just in the span from FY08 to FY09, the NASA Payload Space Station Support Office budget rose from $78M to $96M in attempt to manage the growing manifest, but the potential number of payloads still exceeds available Payload Integration Management manpower. The growth has also increased management difficulties due to the fact that payloads are more frequently added to a flight schedule late in the flow. The current standard ISS template for payload integration from concept to payload turn-over is 36 months, or 18 months if the payload already has a preliminary design. Customers are increasingly requiring a turn-around of 3 to 6-months to meet market needs. The following paper suggests options for streamlining the current payload integration process in order to meet customer schedule needs and reduce costs for both the integration support teams and the developers, without reducing quality or compromising safety. Issues for the key integration areas of planning, training, verification, and safety are presented in a Root-Cause Analysis study, with plausible solutions provided that involve technology and tools already available to the ISS community. Although based upon the ISS process, the payload integration techniques outlined herein also offer an integration template for any space transport endeavor.

Lufkin, Susan N.↗

DOE OSTI2016

RESULTS OF THE 2015 HELIUM PROCESSING OF CEBAF CRYOMODULES

Many conference series have adopted the same The CEBAF accelerator at Jefferson Lab consists of an injec-tor and two linacs connected by arcs. Each linac contains 25 cryomodules that are designed to deliver an integrated energy of 2.2 GeV per pass to an electron beam in order to meet 12 GeV energy requirements. Helium processing is a processing technique that is used to reduce field emis-sion (FE) in SRF cavities. Helium processing of the 50 installed linac cryomodules was seen as necessary to support 12 GeV energy requirements. This paper will describe the processing procedure and summarize the results of this effort.

Drury, Michael A.↗

NASA NTRS2011

NASA's Habitat Demonstration Unit (HDU) Pressurized Excursion Module (PEM) In-Field Demonstration at Desert RATS 2010

This paper describes the construction, assembly, subsystem integration, transportation, and field testing operations associated with the Habitat Demonstration Unit (HDU) Pressurized Excursion Module (PEM) and discusses lessons learned. In a one-year period beginning summer 2009, a tightly scheduled design-develop-build process was utilized by a small NASA "tiger team" to produce the functional HDU-PEM prototype in time to participate in the 2010 Desert Research and Technology Studies (Desert RATS) field campaign. The process required the coordination of multiple teams, subcontractors, facility management and safety staff. It also required a well-choreographed material handling and transportation process to deliver the finished product from the NASA-Johnson Space Center facilities to the remote Arizona desert locations of the field test. Significant findings of this paper include the team s greater understanding of the HDU-PEM s many integration issues and the in-field training the team acquired which will enable the implementation of the next-generation of improvements and development of high-fidelity field operations in a harsh environment. The Desert RATS analog environment is being promoted by NASA as an efficient means to design, build, and integrate multiple technologies in a mission architecture context, with the eventual goal of evolving the technologies into robust flight hardware systems. The HDU-PEM in-field demonstration at Desert RATS 2010 provided a validation process for the integration team, which has already begun to retool for the 2011 field tests that require an adapted architecture.

Tri, Terry O.↗

DOE OSTI2024

Optimization of neutron chopper and optics for CENTAUR, the SANS/WANS diffractometer at the spallation neutron source second target station

Herein this report presents the physics design and optimization of the neutron chopper and optics systems for the CENTAUR instrument, a multifunctional small-angle and wide-angle neutron scattering diffractometer for the Spallation Neutron Source Second Target Station. This instrument will offer a wide range of capabilities, including small-angle neutron scattering with wide Q coverage (e.g., 0.001–20 Å –1 ), providing a tool to investigate structures from atomic to mesoscopic scales simultaneously. To efficiently transport desired neutrons from the compact high-brightness cold source, several innovative designs are utilized: a time-zero chopper with a straight guide system for short-wavelength neutrons, octagonal guides for higher flux, and a correlation chopper to reduce inelastic scattering. The optimization process considers factors such as useable time-integrated flux, instrument resolution, brilliance transfer, divergence, and acceptance diagram uniformity. The overall design prioritizes flexibility to accommodate diverse user requirements.

46 INSTRUMENTATION RELATED TO NUCLEAR SCIENCE AND ↗

NASA NTRS1981

The CELSS program - An overview of its structure and use of computer modelling

NASA has initiated a research program, CELSS, directed at the acquisition of the knowledge and technology required for the development of an autonomous, regenerative life support system. The program is structured to promote effective, cooperative research in fundamental, applied and engineering science. The initial research thrusts involve investigations into problems of food production, waste processing and system control and integration. In the area of food production both conventional, higher plant-based processes as well as chemosynthetic food production technologies are being investigated. Alternative waste processing procedures, both biological and physicochemical, are being examined. Computer based modelling as an aid to design and analysis is an integral part of the approach to system control and management. A mass balance model depicting the flow of elemental mass in a conceptualized closed, regenerative life support system is described.

Averner, M. M.↗

NASA NTRS1987

A space systems perspective of graphics simulation integration

Creation of an interactive display environment can expose issues in system design and operation not apparent from nongraphics development approaches. Large amounts of information can be presented in a short period of time. Processes can be simulated and observed before committing resources. In addition, changes in the economics of computing have enabled broader graphics usage beyond traditional engineering and design into integrated telerobotics and Artificial Intelligence (AI) applications. The highly integrated nature of space operations often tend to rely upon visually intensive man-machine communication to ensure success. Graphics simulation activities at the Mission Planning and Analysis Division (MPAD) of NASA's Johnson Space Center are focusing on the evaluation of a wide variety of graphical analysis within the context of present and future space operations. Several telerobotics and AI applications studies utilizing graphical simulation are described. The presentation includes portions of videotape illustrating technology developments involving: (1) coordinated manned maneuvering unit and remote manipulator system operations, (2) a helmet mounted display system, and (3) an automated rendezous application utilizing expert system and voice input/output technology.

Brown, R.↗

DOE OSTI2020

Analysis of Planar-Cavity Receiver Reactor for Solar Thermochemical Dry-Reforming

Concentrating solar thermal (CST) systems can be leveraged to provide not only heat for power generation, but also for energy storage and thermochemical fuel production. Such solar thermochemical processes have been studied conceptually, from solar thermochemical hydrogen production (STCH) and thermochemical energy storage (TCES), to gasification, reforming, and fuel upgrading by various means. The solar receiver and reactor are critical components in the conversion of solar energy into chemical energy in the form of 'solar fuels'. For effective conversion of solar energy within a coupled solar receiver-reactor, extremely high temperatures are required, thereby demanding a high solar concentration ratio (CR) for efficient operation. This creates a design challenge for the receiver-reactor, as many thermochemical processes involve gas or gas-solid systems that are limited by low heat transfer coefficients. A unique receiver design is proposed that has the potential to incorporate various high-temperature thermochemical processes such as TCES-assisted power generation, methane reforming, or STCH processes. Modeling this receiver and its potential applications requires a full three-dimensional model that accurately captures the interconnected effects of receiver geometry, spatial solar irradiance, complex radiation, reaction kinetics, fluid dynamics, and heat transfer. In this paper we analyze a CST system integrated with this unique planar-cavity receiver-reactor design using the developed model. The model presented in this paper showed where improved thermal management was needed to achieve suitable receiver performance when a dry-methane reforming process is implemented.

14 SOLAR ENERGY↗

NASA NTRS1994

Composite chronicles: A study of the lessons learned in the development, production, and service of composite structures

A study of past composite aircraft structures programs was conducted to determine the lessons learned during the programs. The study focused on finding major underlying principles and practices that experience showed have significant effects on the development process and should be recognized and understood by those responsible for using of composites. Published information on programs was reviewed and interviews were conducted with personnel associated with current and past major development programs. In all, interviews were conducted with about 56 people representing 32 organizations. Most of the people interviewed have been involved in the engineering and manufacturing development of composites for the past 20 to 25 years. Although composites technology has made great advances over the past 30 years, the effective application of composites to aircraft is still a complex problem that requires experienced personnel with special knowledge. All disciplines involved in the development process must work together in real time to minimize risk and assure total product quality and performance at acceptable costs. The most successful programs have made effective use of integrated, collocated, concurrent engineering teams, and most often used well-planned, systematic development efforts wherein the design and manufacturing processes are validated in a step-by-step or 'building block' approach. Such approaches reduce program risk and are cost effective.

Vosteen, Louis F.↗

DOE OSTI2019

Fundamental Advancements in Pre-Chamber Spark Ignition and Emissions Control for Natural Gas Engines

Argonne National Laboratory, the National Renewable Energy Laboratory, Oak Ridge National Laboratory, and Sandia National Laboratories collaborated on research to address barriers for natural gas engine efficiency. This research project focuses on early stage research focusing on pre-chamber spark-ignition (PCSI) to achieve diesel-like efficiency in medium- and heavy-duty natural gas engines by extending the lean dilution limit and/or exhaust gas recirculation (EGR) dilution limit, as well as shortening burn duration, with integrated aftertreatment. This project integrates experimental and simulation based tasks to address four key barriers to market penetration of PCSI for medium- and heavy-duty natural gas engines. These include Inadequate science base and simulation tools to describe/predict the fluid-mechanical and chemical-kinetic processes governing PCSI to enable engineers in industry to optimize designs for efficiency, noise, reliability, pollutant formation, emissions control integration, and drivability; limited ability to extend EGR and/or lean dilution limits at higher loads; increased propensity for PCSI hot-spot pre-ignition at high loads relative to spark ignition; and ineffective methane catalysts for the high engine-out unburned fuel concentrations coupled with low exhaust temperatures (<<400 degrees C) of high efficiency engines.

33 ADVANCED PROPULSION SYSTEMS↗

NASA NTRS2000

An Assessment of the Technical Readiness of the Vapor Phase Catalytic Ammonia Removal Process (VPCAR) Technology

This poster provides an assessment of the technical readiness of the Vapor Phase Catalytic Ammonia Removal Process (VPCAR). The VPCAR technology is a fully regenerative water recycling technology designed specifically for applications such as a near term Mars exploration mission. The VPCAR technology is a highly integrated distillation/catalytic oxidation based water processor. It is designed to accept a combined wastewater stream (urine, condensate, and hygiene) and produces potable water in a single process step which requires -no regularly scheduled re-supply or maintenance for a 3 year mission. The technology is designed to be modular and to fit into a volume comparable to a single International Space Station Rack (when sized for a crew of 6). This poster provides a description of the VPCAR technology and a summary of the current performance of the technology. Also provided are the results of two separate NASA sponsored system trade studies which investigated the potential payback of further development of the VPCAR technology.

Flynn, Michael↗

NASA NTRS2014

SpaceCube v2.0 Space Flight Hybrid Reconfigurable Data Processing System

This paper details the design architecture, design methodology, and the advantages of the SpaceCube v2.0 high performance data processing system for space applications. The purpose in building the SpaceCube v2.0 system is to create a superior high performance, reconfigurable, hybrid data processing system that can be used in a multitude of applications including those that require a radiation hardened and reliable solution. The SpaceCube v2.0 system leverages seven years of board design, avionics systems design, and space flight application experiences. This paper shows how SpaceCube v2.0 solves the increasing computing demands of space data processing applications that cannot be attained with a standalone processor approach.The main objective during the design stage is to find a good system balance between power, size, reliability, cost, and data processing capability. These design variables directly impact each other, and it is important to understand how to achieve a suitable balance. This paper will detail how these critical design factors were managed including the construction of an Engineering Model for an experiment on the International Space Station to test out design concepts. We will describe the designs for the processor card, power card, backplane, and a mission unique interface card. The mechanical design for the box will also be detailed since it is critical in meeting the stringent thermal and structural requirements imposed by the processing system. In addition, the mechanical design uses advanced thermal conduction techniques to solve the internal thermal challenges.The SpaceCube v2.0 processing system is based on an extended version of the 3U cPCI standard form factor where each card is 190mm x 100mm in size The typical power draw of the processor card is 8 to 10W and scales with application complexity. The SpaceCube v2.0 data processing card features two Xilinx Virtex-5 QV Field Programmable Gate Arrays (FPGA), eight memory modules, a monitor FPGA with analog monitoring, Ethernet, configurable interconnect to the Xilinx FPGAs including gigabit transceivers, and the necessary voltage regulation. The processor board uses a back-to-back design methodology for common parts that maximizes the board real estate available. This paper will show how to meet the IPC 6012B Class 3A standard with a 22-layer board that has two column grid array devices with 1.0mm pitch. All layout trades such as stack-up options, via selection, and FPGA signal breakout will be discussed with feature size results. The overall board design process will be discussed including parts selection, circuit design, proper signal termination, layout placement and route planning, signal integrity design and verification, and power integrity results. The radiation mitigation techniques will also be detailed including configuration scrubbing options, Xilinx circuit mitigation and FPGA functional monitoring, and memory protection.Finally, this paper will describe how this system is being used to solve the extreme challenges of a robotic satellite servicing mission where typical space-rated processors are not sufficient enough to meet the intensive data processing requirements. The SpaceCube v2.0 is the main payload control computer and is required to control critical subsystems such as autonomous rendezvous and docking using a suite of vision sensors and object avoidance when controlling two robotic arms.

Xilinx FPGA↗

NASA NTRS2015

Integration of Product, Package, Process, and Environment: A Food System Optimization

The food systems slated for future NASA missions must meet crew nutritional needs, be acceptable for consumption, and use resources efficiently. Although the current food system of prepackaged, moderately stabilized food items works well for International Space Station (ISS) missions, many of the current space menu items do not maintain acceptability and/or nutritive value beyond 2 years. Longer space missions require that the food system can sustain the crew for 3 to 5 years without replenishment. The task "Integration of Product, Package, Process, and Environment: A Food System Optimization" has the objective of optimizing food-product shelf life for the space-food system through product recipe adjustments, new packaging and processing technologies, and modified storage conditions. Two emergent food processing technologies were examined to identify a pathway to stable, wet-pack foods without the detrimental color and texture effects. Both microwave-assisted thermal sterilization (MATS) and pressure-assisted thermal stabilization (PATS) were evaluated against traditional retort processing to determine if lower heat inputs during processing would produce a product with higher micronutrient quality and longer shelf life. While MATS products did have brighter color and better texture initially, the advantages were not sustained. The non-metallized packaging film used in the process likely provided inadequate oxygen barrier. No difference in vitamin stability was evident between MATS and retort processed foods. Similarly, fruit products produced using PATS showed improved color and texture through 3 years of storage compared to retort fruit, but the vitamin stability was not improved. The final processing study involved freeze drying. Five processing factors were tested in factorial design to assess potential impact of each to the quality of freeze-dried food, including the integrity of the microstructure. The initial freezing rate and primary freeze drying temperature and pressure were linked to final product quality in freeze-dried corn, indicating processing modifications that could lead to improved product shelf life. Storage temperatures and packaging systems were also assessed for the impact to food quality. Reduced temperature storage had inconclusive impact to the progression of rancidity in butter cookies. Frozen storage was detrimental to fruit and vegetable textural attributes but refrigerated storage helped to sustain color and organoleptic ratings for plant-based foods. With regard to packaging systems, the metallized film overwrap significantly decreased the progression of the rancidity of butter cookies as compared to the highest barrier non-metallized film. The inclusion of oxygen scavengers resulted in noticeable moisture gains in butter cookies over time, independent of packaging film systems. Neither emergent processing technology nor the freeze dry optimization resulted in compelling quality differences from current space food provisions such that a five-year shelf life is likely with these processing changes alone. Using a combination of refrigeration and PATS processing is expected to result in organoleptically-acceptable fruit quality for most fruits through five years. The vitamin degradation will be aided somewhat by the cold temperatures but, given the labile nature of vitamin C, a more stable fortification method, such as encapsulation, should also be investigated to ensure vitamin delivery throughout the product life. Similarly, significant improvement to the packaging film used in the MATS processing, optimization of formulation for dielectric properties, vitamin fortification, and reduced temperature storage should be investigated as a hurdle approach to reach a five year shelf life in wet-pack entrees and soups. Baked goods and other environmentally-sensitive spaceflight foods will require an almost impenetrable barrier to protect the foods from oxygen and moisture ingress but scavengers and reduced storage temperature did not improve baked good shelf life and are not recommended at this time for these foods.

Cooper, Maya R.↗

NASA NTRS2004

Onboard FPGA-based SAR processing for future spaceborne systems

We present a real-time high-performance and fault-tolerant FPGA-based hardware architecture for the processing of synthetic aperture radar (SAR) images in future spaceborne system. In particular, we will discuss the integrated design approach, from top-level algorithm specifications and system requirements, design methodology, functional verification and performance validation, down to hardware design and implementation.

spaceborne systems↗

NASA NTRS2011

Qualification of emerging point-of-load regulators for next generation power systems

As demand for high-speed, on-board, digital-processing integrated circuits (ICs) on spacecraft increases (FPGAs and DSPs in particular), the need for the next generation point-of-load (POL) regulator becomes a prominent design issue. Shrinking process nodes have resulted in core rails dropping to values close to 1.0 V, drastically reducing margin to standard switching converters or regulators that power digital ICs. The objectives of this study are to first identify reliability issues or additional space reliability requirements that might not be addressed for commercial application of POL converters; second, to study the performances of existing or emerging POL converters (including linear regulators) within a practical two-stage power distribution architecture; and, finally, to identify points of failure at extreme temperatures (low and high) beyond specifications.

Leon, Rosa↗

NASA NTRS2005

The SMART Theory and Modeling Team: An Integrated Element of Mission Development and Science Analysis

When targeting physical understanding of space plasmas, our focus is gradually shifting away from discovery-type investigations to missions and studies that address our basic understanding of processes we know to be important. For these studies, theory and models provide physical predictions that need to be verified or falsified by empirical evidence. Within this paradigm, a tight integration between theory, modeling, and space flight mission design and execution is essential. NASA's Magnetospheric MultiScale (MMS) mission is a pathfinder in this new era of space research. The prime objective of MMS is to understand magnetic reconnection, arguably the most fundamental of plasma processes. In particular, MMS targets the microphysical processes, which permit magnetic reconnection to operate in the collisionless plasmas that permeate space and astrophysical systems. More specifically, MMS will provide closure to such elemental questions as how particles become demagnetized in the reconnection diffusion region, which effects determine the reconnection rate, and how reconnection is coupled to environmental conditions such as magnetic shear angles. Solutions to these problems have remained elusive in past and present spacecraft missions primarily due to instrumental limitations - yet they are fundamental to the large-scale dynamics of collisionless plasmas. Owing to the lack of measurements, most of our present knowledge of these processes is based on results from modern theory and modeling studies of the reconnection process. Proper design and execution of a mission targeting magnetic reconnection should include this knowledge and have to ensure that all relevant scales and effects can be resolved by mission measurements. The SMART mission has responded to this need through a tight integration between instrument and theory and modeling teams. Input from theory and modeling is fed into all aspects of science mission design, and theory and modeling activities are tailored to SMART needs during mission development and science analysis. In this presentation, we will present an overview of SMART theory and modeling team activities. In particular, we will provide examples of science objectives derived from state-of-the art models, and of recent research results that continue to be utilized in SMART mission development.

Hesse, Michael↗

DOE OSTI2025

Mechanical separations of corn stover anatomical fractions in an integrated feedstock preprocessing system: An experimental and data-driven modeling study

High variabilities of material attributes in lignocellulosic biomass present risks for biofuel and biochemical productions and must be mitigated via preprocessing. Since almost no mechanical device is originally designed for processing biomass, how to operate existing apparatuses with efficient performance has not been investigated extensively. This work presents a study on an integrated screening and air classification to separate cobs and stalks from husks and leaves in corn stover. Prototype machine learning models were developed to assess the feasibility of predicting the process outcome based on the measurable parameters. The models trained upon limited experimental data rendered decent predictive accuracy of yield and purity. The experimental data and modeling results collectively suggest decreasing throughput leads to a higher purity. To the contrary, if throughput increases, a lower purity is likely. A possible trade-off between yield and purity of the separated streams indicates the need for optimal combinations of feedstock size, moisture, and throughput to achieve optimized separations. The results of this study also suggest the need to further improve model predictability by developing more accurate formulations for physics governing the integrated unit operations. To accomplish this, additional experimental data needs to be generated for model training.

09 - BIOMASS FUELS↗

NASA NTRS2013

Environmentally Friendly Rotorcraft Concepts: 2011-2014: US/France MoA Helicopter Aeromechanics - Task 5

Motivation: Greenhouse gas concentrations have increased well beyond their pre-industrial levels due to human activities; Aircraft emissions are becoming regulated in industrialized nations, so future rotorcraft will need to be designed for minimal environmental impact. Objectives: Determine suitable metrics to measure environmental impact of rotorcraft, focusing first on air pollution; Integrate performance metrics with rotorcraft design codes; Generate rotorcraft designs with minimal environmental impact. Outcomes: Obtain an understanding of how targeting reduced emissions affects the rotorcraft design process; Advance the capability of existing rotorcraft design tools to include environmental performance metrics. Tools: Evaluation and predesign - NDARC (NASA Design and Analysis of Rotorcraft) and CREATION (Concepts of Rotorcraft Enhanced Assessment Through Integrated Optimization Network); Flight simulation - CAMRAD II (Comprehensive Analytical Model of Rotorcraft Aerodynamics and Dynamics) and HOST (Helicopter Overall Simulation Tool).

Environmentally Friendly↗